Tufting mechanism for producing shag fabrics

ABSTRACT

This disclosure relates to tufting machines for economically producing relatively long nap tufted fabrics hereinafter referred to as shag pile or shag fabrics. The disclosure is more specifically directed to a looper construction for a tufting machine and having means for defining the path of travel of the loops of yarn about said looper such that when the loops are severed one leg of said loops will be substantially longer than the other.

United States Patent Charles W. Watkins Soddy. Tenn.

June 23, 1970 July 27, 1971 The Singer Company New York, NY.

Inventor Appl. No. Filed Patented Assignee TUFTING MECHANISM FOR PRODUCING SHAG FABRICS 16 Claims, 12 Drawing Figs.

11.8. CI 112/79 R Int. Cl. ..D05c 15/22, D05c 15/24 Field of Search 112/79 R. 79 A, 266, 410

[56] References Cited UNITED STATES PATENTS 2,423,607 7/1947 McCutchen 112/79 R 3,096,734 7/1963 Card 112/79 R 3,152,563 10/1964 Broadrick 112/79 R 3,162,155 12/1964 Charles 112/79 R 3,203,379 8/1965 Dedmon et al. 112/79 R Primary Examiner-James R. Boler AttorneysMarshall J. Breen, Chester A. Williams, Jr. and

Julian Falk ABSTRACT: This disclosure relates to tufting machines for economically producing relatively long nap tufted fabrics hereinafter referred to as shag pile or shag fabrics. The disclosure is more specifically directed to a looper construction for a tufting machine and having means for defining the path of travel of the loops of yarn about said looper such that when the loops are severed one leg of said loops will be substantially longer than the other.

PATENTED JUL2 7 L971 sum 1 OF 3' WITNESS= Fig.4

INVENTOR.

Charles W. Watkins ATTORNEY PATENTEnJuLzusn I 3,595,1 4

sum 3 or 3 Charles W. Watkins.

AT TORNE Y TUFTING MECHANISM FOR PRODUCING SIIAG FABRICS BACKGROUND OF THE INVENTION Due to the present popularity of shag fabrics, in particular shag carpets, there has been a demand for increased production of this type of fabric. Generally, the machines which have been heretofore used in making high pile fabrics are relatively restricted in that the length of the nap which can be produced is substantially limited by the maximum limit of the length of the needle stroke. In order to increase the length of the nap so as to produce shag-type carpets longer needles have been used for increasing the distance the yarn is carried through the backing fabric. However, due to the length of such needles,

the fabric feed must be slowed down in order to avoid damaging theneedles since such needles remain in the backing fabric for a longer period of time. Further, such machines produce a shag fabric wherein both legs of the loops of yarn are severed at substantially a maximum length thereby resulting in a relatively dense long pile which is often unnecessary in shag fabrics thereby further increasing the cost of the fabric due to the relative excess of yarn which must be used.

GENERAL DESCRIPTION OF THE INVENTION In the present invention a shag fabric can be produced without requiring any substantial increase in needle stroke and wherein conventional needles maybe used with the machine operating at conventional speeds. The machine includes a novel looper construction having means for intercepting the loops of yarn from the needle and increasing the length of the path of travel of the loop about said looper and has means for severing the loop such that, when severed, one leg of the loop is substantially longer than the other whereby the longer loop produces a relatively long nap or pile and the shorter loop produces a dense backfill between the long nap. More'specifically, the looper includes a first bill portion for intercepting loops of yarn-from the needle, a second bill portion which is spaced from said first bill portion in a direction toward the needles and includes a cutting edge which cooperates with a knife mechanism for severing one leg of the loops adjacent said cutting edge. A yarn-loop-engaging means is provided on said looper which serves to increase the path of travel of the loop about said looper. The loops will, therefore, be disposed about said first and second bill portion and be increased in their path of travel by said yarn-loop-engaging means; and since the loops will be severed adjacent the cutting edge of the second bill portion, one leg of the loops will be substantially longer than the other so that there will be one relatively long pile produced and one relatively short pile from each loop. Since substantially the same needles can be used as in a standard tufting machine, there is no reason for a reduction in speed as is the case in the aforementioned machines. Further, since the long nap is produced by providing only one long leg and oneshort leg, a lesser amount of yarn will be required relatively speaking as compared with the amount of yarn required in the prior machine described above. This relatively smaller amount of yarn required and the fact that standard production speeds can be used with the machines of the present invention, will result in the capability of increased production of the shag-type carpets and will, as a result, make such production more economical.

Accordingly, it is one object of the invention to provide a novel and improved tufting machine for producing long nap pile fabrics.

It is another object of the invention to produce a novel and improved tufting machine including a novel looper means.

It is still another object of the present invention to provide a novel and improved looper means for 'a tufting machine.

It is a further object of the present invention to provide a novel andimproved tufting machine for economically producing shag fabrics.

Other objects and advantages of the invention will become apparent upon reading the following detailed description with the accompanying drawings wherein:

FIG. 1 is a front view ofa portion of the tufting elements of a tufting machine;

FIG. 2 is a perspective view of one embodiment of a looper of the present invention;

FIG. 3 is a top view of the looper of FIG. 2 and including a portion of a knife mechanism;

FIG. 4 is an illustration of a type of fabric produced by the present invention;

FIG. 5 is a front view ofa tufting mechanism similar to that shown in FIG. I but showing a second embodiment of the invention;

FIG. 6 is a perspective view of a portion of the mechanism shown in FIG. 5;

FIG. 7 is a top view ofa portion of the mechanism shown in FIG. 5;

FIG. 8 is a side view ofthe mechanism shown in FIG. 6;

FIG. 9 is a front view of another embodiment of the inventron;

FIG. 10 is a side view of the looper shown in FIG. 9;

FIG. 11 is a top view of the looper shown in FIGS. 9 and 10; and

FIG. 12 is a perspective view ofa further embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. I, there is shown therein a portion of the tufting mechanism ofa tufting machine for producing pile fabrics. The tufting machine includes a needle 10, or a plurality of such needles, which is disposed for endwise movement by a suitable drive mechanism (not shown) as is well known. The needle or needles carry a yarn Y for penetration through a backing fabric F in order to project a loop of yarn through said backing fabric. The backing fabric F is supported on a support plate 12 of known structure and is advanced across said support plate by mechanism not illustrated but which is well known in the art. As the needle 10 projects a loop of yarn through the backing fabric, the loop is intercepted by a looper generally designated 14 which looper retains the loop as the needle recedes upwardly through the backing fabric on its return stroke so that a pile loop is formed on the downward face of the backing fabric F. If it is desired to cut the loops, a knife 16 is disposed for cooperating relationship with the looper 14 to sever the loops as they are fed onto the looper 14 during feeding of the backing fabric. If, however, it is desired to produce only loop pile, the knife mechanism is eliminated and the direction of the looper is reversed so that the loops feed off the looper as the backing fabric F is advanced. The structure thus far described is conventional in the tufting art.

As stated above, the invention relates to a construction for producing shag fabrics and, in particular, one wherein each loop is severed to produce one long pile element and one short pile element therefrom. In order to carry out this purpose of the invention, a novel looper mechanism is provided. With reference to FIG. 2, the looper 14 includes a body portion 18 which is constructed so as to be fit into a support mechanism or looper block such as that illustrated in FIG. 6 at 20. The head or upper portion 22 of the looper 14 includes bill means comprising a first elongated bill portion 24 which extends from said head portion 22 and a second bill portion 26 which is vertically spaced from said first bill portion 24 in the direction of the needle 10 as viewed in FIG. 1. As seen in FIG. 2, the first or lower bill portion 24 is relatively longer than the second bill portion 26 to insure that said first bill portion 24 will pick up the loop from the needle as the looper intercepts the path of travel of the needle, as will be more fully explained hereinafter. A loop engaging means 28 is disposed between the first and second bill portions and in spaced relationship relative thereto. As viewed in FIG. 2, the loop-engaging means 28 may be attached to the head portion 22 of the looper as by rivets 30 or the like but it should be understood that the means 28 may be made as an integral part of the looper as by casting or stamping, or the like. Again, as viewed in FIG. 2, it will be seen that the outer portion of the means 28 is bent so as to extend in the direction of the knife mechanism 16 and outwardly from the first and second bill portions 24 and 26. This bent portion 32 serves to pick up one leg ofa loop yarn intercepted by the first bill portion 24 and guides said leg between the first and second bill portions 24 and 26, as illustrated in FIG. 1. Due to the path of travel of the one leg of the loop of yarn around the loop-engaging means 28 between the first and second bill portions 24 and 26, the length of the path of travel of said one leg will be increased in comparison with that length of the leg which would be present in absence of the means 28.

As is well known in the art, the loopers in a tufting machine may be disposed for motion toward and away from the reciprocating needle so as to intercept and pick up a loop of yarn from the needle during the downward stroke thereof. Further, in so-called cut pile machines the backing fabric is advanced in a direction opposite to the direction in which the looper is facing so that the loops are fed onto the looper where they will be cut by the knife mechanism 16 as they reach the rear portion of the looper. Therefore, as opposed to that illustrated in the drawings, there is normally more than one loop disposed on a looper at any one time with the firstmost loop being severed as it advances towards the rear of the looper. Only one loop has been shown on the looper in the drawings for purposes of clarity of illustration.

As stated above, a knife mechanism 16 is provided for cooperation with the looper 14 to provide a cut pile. The knife 16 includes a cutting edge 34 at its uppermost portion which is disposed for cooperating with a cutting edge 36 on one edge of the second bill portion 26 which edge is disposed on the side opposite to that wherein the loop-engaging means 28 is supported. The knife mechanism 16 may also be supported for movement in combination with the looper 14 so that a scissorslike action is provided for cutting the yarn Y. The knife mechanism 16 may also be supported in a stationary disposition with the looper moving relative thereto to cut the yarns Y.

As further shown in FIGS. 1 and 2, a rod member 38 is disposed between the first and second bill portions 24 and 26 and the outer ends thereof. Member 38 serves to guide the loop of yarn to ensure that the second bill portion 26 splits the loop of yarn and so that the one leg of the loop of yarn to be cut will be guided toward the cutting edge of said second bill 26. FIG. 1 illustrates a loop of yarn which has been intercepted by the first bill portion 24 and has been moved to the rear portion of the looper wherein it is in a position to be cut by the cooperating cutting edges of the knife 16 and the second bill portion 26. As will be apparent from FIG. 1 and FIG. 4, when the loop is cut or severed the cut will be made in a position substantially off center from the mid portion of the loop. More specifically, as shown in FIG. 4, when the loop is cut, a substantially long leg Y will be formed which defines a long pile or shag pile and a relatively short leg Y will be formed which provides a filler pile between the long pile so that a shag rug having a long nap with a relatively dense appearance can be made through the structure previously described.

FIGS. -8 illustrate a second embodiment of the invention with like parts being shown by like numerals. In the second embodiment of the invention, looper mechanism is constructed in two separate pieces which cooperate to bring about the same result as that shown in the embodiments of FIGS. l4. The looper mechanism 15 comprises a first looper part which is disposed in the looper block and includes a first bill portion 40 and a body portion 42 which is supported in the looper block 20. Referring to FIGS. 6 and 7, it will be seen that the first bill 40 includes an upstanding portion at its outer end thereof designated as 44. similar to the rod member 38 of the first embodiment, which portion 44 engages the outer extremity of the bill portion 46 or second bill portion provided on the looper 48. The looper 48 includes a body portion 50 which is likewise supported in the looper block 20 but in spaced relationship to the body portion 42 of the looper part 40. As seen in FIG. 7, the first bill portion 40 is relatively longer than second bill portion 46 to ensure that the loop of yarn on the needle 10 is intercepted by said first bill portion. Further, the first bill portion 40 includes a bent portion 52, or loop-engaging means, which is bent from the body portion 42 thereof in a direction toward the second bill portion 46 such that the upstanding portion 44 is in line with the outermost portion of the second bill portion 46. The second bill portion 46 further includes a cutting edge 53 which is disposed for cooperating relationship with a cutting edge 55 on the knife 16 in a manner as described in connection with the first embodiment. The cutting edge 53 on the first bill portion 46 is disposed on its side thereof opposite to the side on which the first bill 40 portion is disposed. The manner of operation of the second embodiment is similar to that as described in connection with the first embodiment wherein the loop is first intercepted by the first bill portion 40 and moved toward the rear ofthe looper mechanism as the fabric is fed in a direction opposite to the front of the looper mechanism or toward looper block 20. As the loop is fed along the looper mechanism, the path of travel of the loop of yarn Y will be increased as it travels over the bent portion or loop-engaging means 52 on the first bill portion 40 since the first bill portion and second bill portion are relatively spaced apart due to their spaced mounting in looper block 20. The disposition of the loop of yarn as it comes into position for cutting, is illustrated in FIG. 5, where it is shown that the path of travel of the loop has been increased due to the above-described structure of the looper mechanism. When the loop is in the proper position, the relative motion between the looper mechanism and the knife mechanism will sever the loop and provide a shag-type fabric as illustrated in FIG. 4.

FIGS. 9-l1 show a third embodiment of the invention. The looper 54 of FIGS. 9-11 comprises a body portion 56 including a horizontal or bent portion 58 which is provided for disposal in a looper block such as the looper block 20 described above. In the embodiment of FIGS. 9ll, the looper 54 is of unitary construction and is fabricated by stamping, casting or the like. Thus, the first bill portion 60, the second bill portion 62 and the loop-engaging means are all interconnected in a single piece construction with the looper body portions 56 and 58. Also, the upstanding portion 64 is interconnected with the first and second bill portions as well as the loop-engaging means 66. As shown in FIGS. 9 and 11, tht loop-engaging means 66 is bent or is disposed in laterally spaced relationship to the first and second bill portions so that a leg of the yarn loop will have its path of travel lengthened in the manner described above. In operation the end point 68 o" the first bill portion will seize the loop of yarn and, as the loop passes along the looper toward the rear thereof, one leg of said loop will have its path of travel lengthened by the laterally displaced loop-engaging means 66. The second bill portion is provided with a cutting edge 70 for cooperation with the cutting edge on a knife, as previously described fo cutting the loop into one long leg or shag pile and a short leg which forms as a fill between the long pile legs. As will be apparent the operation of the looper shown in FIGS. 9-11, is the same as that described in the above embodiment.

FIG. 12 illustrates a further embodiment of the invention which is similar to the embodiment shown in FIGS. 6-8 and like numerals with subscripts having been used in FIG. 12. As shown therein, the looper 15a is of two-piece construction but with the body portions 42a and 50a being supported in the same slot in the looper block 20a. The loop-engaging means 520 is laterally offset from the adjacent looper body 50a so as to increase the path of travel of one leg of a loop of yarn, as described above. Also, in this embodiment, the upstanding portion 44a is slightly offset at its uppermost end and overlaps the point of the second bill portion 46a. In all other respects .the structure and function of the looper 15a is similar to that of the looper 15 of FIGS. 6-8 with the additional exception than theother leg.

of the vertical orientation of the looper body portions 42a and 50a in FIG. 12 as opposed to the horizontal orientation of the bottom portion of the looper body portions 42 and 50 of the looper I5 of FIGS. 6-8. The embodiment of FIG. 12 has the advantage that it may be used in closer or finer gauge tufting than the embodiment of FIGS. 6 8.

It will, therefore, be seen that an invention is provided wherein shag fabrics can be formed'at normal tufting speeds and by a process which makes economical use of the yarn. Thus, the construction of the. invention provides a means whereby shag fabrics can be produced in increased production over that previously possible and in a more economical manner.

Having thus set forth the nature of the invention, what I claim herein is: v Y

I I. In a tufting machine for forming tufted fabrics including means for supporting a backing fabric and yarn-carrying needle means disposed on one side of said support means and adapted to penetrate and to carry a loop of yarn through said backing fabric, looper means disposed on the opposite sideof said support means from said needle means and including bill means having a first bill portion disposed for seizing loops of yarn presented by said needle means, a second bill portion spaced from said first bill portion, and having a cutting edge, knife means having a cutting edgevfor cooperating with the cutting edge on said second bill portion to sever loops of yarn on said second bill portion, for forming cut pile, and yarnloop-engaging means for lengthening thepath of loops of yarn about said first and second bill portions such that when said loop is severed between said knife means and said second bill portion, one leg of said out loop will be substantially longer 2. In a tufting machine as recited-in claim 1 wherein said second bill portion is spaced from said first bill portion in a direction toward said needle means;

3. In a tufting machine as recited in claim I wherein said yarn-loop-engaging means comprises an additional member disposed between said first and second bill portions and having a portion thereon for deflecting and increasing the path of travel of one leg of a yarn loop between said first and second bill portions.

4. In a tufting machine as recited in claim 3 wherein said member has an end portion for engaging one leg of a loop of yarn, said end portion extending in a direction toward the cutting edge side of said second bill portion and substantially therebeyond such that one leg of'a loop of yarn seized by said first bill portion will be intercepted by said member and guided around said member and between said first and second bill portions.

5. In a tufting machine as recited in claim 4 comprising means interconnecting the outer end portions of said first and second bill portions for guiding the loop of yarn such that said second bill portion splits the loop of yarn and the said one leg of the loop of yarn to be cut will be guided toward the cutting edge of said second bill portion.

6. In a tufting machine as recited in claim 1 wherein said first bill portion is longer than said second bill for enabling said first bill portion to seize the loop of yarn from said needle means.

7. In a tufting machine as recited in claim 3 wherein said first bill portion is longer than said second bill portion and said member for enabling said first bill to seize the loop of yarn from said needle means.

8. In a tufting machine as recited in claim 2 wherein said first bill portion is spaced laterally from said second bill portion for increasing the length of one leg of the loop of yarn between said cutting edge and said first bill portion.

9. In a tufting machine as recited in claim 8 wherein said first bill portion includes an upstanding end member thereon which engages an end of saidsecond bill portion for guiding the loop of yarn such that said second bill portion splits the loo of'yarn and the said one leg of the loop of yarn to be cut wil be guided toward the cutting edge of said second bill portion.

10. In a tufting machine as recited in claim 2 wherein said first bill portion extends from a position laterally spaced from said second bill portion and includes a bent area extending said first bill portion in a lateral direction toward and in substantial lateral alignment with said second bill portion at the outer ends thereof such that when a loop of yarn is seized by said first bill portion the path of travel of one leg thereof will be increased as said loop travels toward the rear portion of said first bill portion.

11. In a tufting machine as recited in claim 2 wherein said first and second bill portions are supported in laterally spaced disposition in a looper block support means.

12. In a tufting machine as recited in claim 1 wherein said first and second bill portions are integrally formed on said looper means.

13. In a tufting machine as recited in claim 2 wherein said first and second bill portions are joined at one end thereof and form a loop-engaging point on said looper means.

I4. In a tufting machine as recited in claim 13 wherein said first bill portion is displaced laterally from said second bill por tion in a region between said loop-engaging point and the body of said looper means.

15. In a tufting machine as recited in claim 14 wherein said looper means is of one-piece construction.

16. In a tufting machine as recited in claim 2 wherein said first and second bill portions are provided on separate looper body members with said looper body members being supported in a common support groove in a looper block support means. 

1. In a tufting machine for forming tufted fabrics including means for supporting a backing fabric and yarn-carrying needle means disposed on one side of said support means and adapted to penetrate and to carry a loop of yarn through said backing fabric, looper means disposed on the opposite side of said support means from said needle means and including bill means having a first bill portion disposed for seizing loops of yarn presented by said needle means, a second bill portion spaced from said first bill portion, and having a cutting edge, knife means having a cutting edge for cooperating with the cutting edge on said second bill portion to sever loops of yarn on said second bill portion, for forming cut pile, and yarn-loop-engaging means for lengthening the path of loops of yarn about said first and second bill portions such that when said loop is severed between said knife means and said second bill portion, one leg of said cut loop will be substantially longer than the other leg.
 2. In a tufting machine as recited in claim 1 wherein said second bill portion is spaced from said first bill portion in a direction toward said needle means.
 3. In a tufting machine as recited in claim 1 wherein said yarn-loop-engaging means comprises an additional member disposed between said first and second bill portions and having a portion thereon fOr deflecting and increasing the path of travel of one leg of a yarn loop between said first and second bill portions.
 4. In a tufting machine as recited in claim 3 wherein said member has an end portion for engaging one leg of a loop of yarn, said end portion extending in a direction toward the cutting edge side of said second bill portion and substantially therebeyond such that one leg of a loop of yarn seized by said first bill portion will be intercepted by said member and guided around said member and between said first and second bill portions.
 5. In a tufting machine as recited in claim 4 comprising means interconnecting the outer end portions of said first and second bill portions for guiding the loop of yarn such that said second bill portion splits the loop of yarn and the said one leg of the loop of yarn to be cut will be guided toward the cutting edge of said second bill portion.
 6. In a tufting machine as recited in claim 1 wherein said first bill portion is longer than said second bill for enabling said first bill portion to seize the loop of yarn from said needle means.
 7. In a tufting machine as recited in claim 3 wherein said first bill portion is longer than said second bill portion and said member for enabling said first bill to seize the loop of yarn from said needle means.
 8. In a tufting machine as recited in claim 2 wherein said first bill portion is spaced laterally from said second bill portion for increasing the length of one leg of the loop of yarn between said cutting edge and said first bill portion.
 9. In a tufting machine as recited in claim 8 wherein said first bill portion includes an upstanding end member thereon which engages an end of said second bill portion for guiding the loop of yarn such that said second bill portion splits the loop of yarn and the said one leg of the loop of yarn to be cut will be guided toward the cutting edge of said second bill portion.
 10. In a tufting machine as recited in claim 2 wherein said first bill portion extends from a position laterally spaced from said second bill portion and includes a bent area extending said first bill portion in a lateral direction toward and in substantial lateral alignment with said second bill portion at the outer ends thereof such that when a loop of yarn is seized by said first bill portion the path of travel of one leg thereof will be increased as said loop travels toward the rear portion of said first bill portion.
 11. In a tufting machine as recited in claim 2 wherein said first and second bill portions are supported in laterally spaced disposition in a looper block support means.
 12. In a tufting machine as recited in claim 1 wherein said first and second bill portions are integrally formed on said looper means.
 13. In a tufting machine as recited in claim 2 wherein said first and second bill portions are joined at one end thereof and form a loop-engaging point on said looper means.
 14. In a tufting machine as recited in claim 13 wherein said first bill portion is displaced laterally from said second bill portion in a region between said loop-engaging point and the body of said looper means.
 15. In a tufting machine as recited in claim 14 wherein said looper means is of one-piece construction.
 16. In a tufting machine as recited in claim 2 wherein said first and second bill portions are provided on separate looper body members with said looper body members being supported in a common support groove in a looper block support means. 